Aircraft bay blankets that provide enhanced drainage features

ABSTRACT

Systems and methods are provided for insulation and moisture drainage. One exemplary embodiment is an apparatus comprising a bay blanket configured to insulate an aircraft. The bay blanket includes insulation, and a first waterproof lip that protrudes from the insulation in an outboard direction towards a frame of the aircraft and extends along a length of a leftward side of the bay blanket. The bay blanket also includes a second waterproof lip that protrudes from the insulation in an outboard direction towards the frame of the aircraft along a length of a rightward side of the bay blanket.

FIELD

The disclosure relates to the field of insulation, and in particular, toinsulation for aircraft.

BACKGROUND

Aircraft may use insulation to prevent internal components fromexperiencing substantial temperature shifts when the aircraft changeselevation between landing and flight. The insulation also helps duringsustained flight at flight altitude, and while the aircraft is locatedon the ground in hot weather or cold weather. For example, aircraftinsulation in a cabin of a passenger aircraft ensures that passengersremain comfortable even when the temperature outside the aircraft variessubstantially.

While an aircraft is in flight, moisture rises from the aircraft cabinand penetrates through insulation in the aircraft. The moisture thencondenses out of the air and freezes to form ice crystals on the insidesurface of the skin of the aircraft. When the skin of the aircraft isexposed to above-freezing temperatures, the ice crystals can melt. Thewater drips off of the skin of the aircraft and onto insulationblankets. There are penetrations/holes in the insulation blankets.Hence, the water running on top of the insulation can leak through thesepenetrations and drip onto the cabin interior, including ceilings andstowage bins. If this water gets past the ceilings and stowage bins, itcan drip into the passenger cabin or cargo area, which is undesirable.

SUMMARY

Embodiments described herein enhance aircraft insulation by providingenhanced drainage features for aircraft bay blankets that insulate bayswithin the frame of an aircraft. The bay blankets described hereininclude tabs/protrusions/lips that are capable of substantiallypreventing water from flowing sideways off of the bay blanket. Thisensures that water that drips onto the bay blanket from the skin of anaircraft follows the contours of the bay blanket and is directed awayfrom the aircraft cabin. In short, dripping moisture is trapped by thebay blanket and drains along drainage channels defined by the bayblanket without entering the aircraft cabin.

One exemplary embodiment is an apparatus comprising a bay blanketconfigured to insulate an aircraft. The bay blanket includes insulation,and a first waterproof lip that protrudes from the insulation in anoutboard direction towards a frame of the aircraft and extends along alength of a leftward side of the bay blanket. The bay blanket alsoincludes a second waterproof lip that protrudes from the insulation inan outboard direction towards the frame of the aircraft along a lengthof a rightward side of the bay blanket.

A further exemplary embodiment is an apparatus that includes a frame ofan aircraft and a bay blanket. The bay blanket includes insulation and afirst waterproof lip that protrudes from the insulation in an outboarddirection towards the frame and extends along a length of a leftwardside of the bay blanket. The bay blanket also includes a secondwaterproof lip that protrudes from the insulation in an outboarddirection towards the frame and extends along a length of a leftwardside of the bay blanket. The apparatus further includes fixationelements that affix each waterproof lip of the bay blanket to the frame,and fixation elements that affix a center of the bay blanket to theframe. The bay blanket hangs from the fixation elements to form adual-gutter pathway for channeling water in the aircraft.

A further embodiment is a method of draining water for an aircraft. Themethod includes receiving water along an outboard surface of a bayblanket comprising insulation. The method further includes deflectingwater traveling laterally across the bay blanket back towards a centerof the bay blanket (e.g., by use of waterproof lips that protrude fromthe insulation in an outboard direction towards a frame of the aircraftand extend along left and right sides of the insulation). Additionally,the method includes draining the water along the outboard surface of thebay blanket downward towards a drain of the aircraft.

A further embodiment is a method that includes selecting a bay blanket,orienting waterproof lips of the bay blanket towards an outboard portionof an aircraft, and affixing the bay blanket to a frame of the aircraft,thereby enabling the bay blanket to hang from the frame and form agutter for draining water.

Other exemplary embodiments (e.g., methods and computer-readable mediarelating to the foregoing embodiments) may be described below. Thefeatures, functions, and advantages that have been discussed can beachieved independently in various embodiments or may be combined in yetother embodiments further details of which can be seen with reference tothe following description and drawings.

DESCRIPTION OF THE DRAWINGS

Some embodiments of the present disclosure are now described, by way ofexample only, and with reference to the accompanying drawings. The samereference number represents the same element or the same type of elementon all drawings.

FIG. 1 is a diagram of an aircraft in an exemplary embodiment.

FIG. 2 is a diagram illustrating moisture flow in an aircraft in anexemplary embodiment.

FIG. 3 is a diagram illustrating section of aircraft fuselage in anexemplary embodiment.

FIG. 4 is a diagram illustrating section of insulated aircraft fuselagein an exemplary embodiment.

FIG. 5 is a side view of overlapping bay blankets of an aircraft in anexemplary embodiment.

FIG. 6 illustrates a bay blanket in a resting configuration in anexemplary embodiment.

FIG. 7 illustrates a bay blanket hanging from fixation elements in aninstalled configuration in an exemplary embodiment.

FIG. 8 illustrates a cut-through front view of an installed bay blanketin an exemplary embodiment.

FIG. 9 is a cut-through diagram illustrating unfolded lips of a bayblanket in an exemplary embodiment.

FIG. 10 is a cut-through diagram illustrating unfolded lips of a bayblanket in an exemplary embodiment.

FIGS. 11-13 illustrate a lower portion of a bay blanket in an exemplaryembodiment.

FIG. 14 is a block diagram of a bay blanket in an exemplary embodiment.

FIG. 15 is a flowchart illustrating a method for installing a bayblanket in an exemplary embodiment.

FIG. 16 is a flowchart illustrating a method for draining water via abay blanket in an exemplary embodiment.

FIG. 17 is a flow diagram of aircraft production and service methodologyin an exemplary embodiment.

FIG. 18 is a block diagram of an aircraft in an exemplary embodiment.

DESCRIPTION

The figures and the following description illustrate specific exemplaryembodiments of the disclosure. It will thus be appreciated that thoseskilled in the art will be able to devise various arrangements that,although not explicitly described or shown herein, embody the principlesof the disclosure and are included within the scope of the disclosure.Furthermore, any examples described herein are intended to aid inunderstanding the principles of the disclosure, and are to be construedas being without limitation to such specifically recited examples andconditions. As a result, the disclosure is not limited to the specificembodiments or examples described below, but by the claims and theirequivalents.

FIGS. 1-4 illustrate moisture flow in an exemplary aircraft, while FIGS.5-14 illustrate systems that reduce the potential for condensed moistureto enter the cabin of an exemplary aircraft. FIG. 1 is a diagram of anaircraft 100 in an exemplary embodiment. Aircraft 100 includes nose 110,wings 120, fuselage 130, and tail 140. FIG. 1 also illustrates adownward direction (Z) indicating the expected direction in which theforce of gravity will pull liquid water on aircraft 100.

FIG. 2 is a cross-section view of aircraft 100 indicated by view arrows2 in FIG. 1. FIG. 2 illustrates a circular portion of aircraft fuselage130. Fuselage 130 includes floor 233, ceiling 232, and sidewalls 231. Asshown in FIG. 2, an outboard direction proceeds towards an externalsurface of aircraft 100. An inboard direction proceeds towards theinterior of aircraft 100. Passengers in aircraft 100 may congregate incabin 230 during flight. Inside of fuselage 130 (e.g., in cabin 230),passenger respiration and other sources of water cause moisture 240 toenter the air in cabin 230. For example, warm exhaled air includesmoisture 240 and rises upward. Some of this air rises through ceiling232. Furthermore, some warm air continues to rise upward throughinsulation 220 into a space 250 between insulation 220 and aircraft skin210.

At high altitude, skin 210 is cooled by the outside air to belowfreezing temperatures. This causes water to condense out of the air andfreeze onto skin 210 as ice 242. Ice 242 melts into water droplets 244upon aircraft 100 descending to for landing. These droplets 244 travelthrough space 250 into drainage channel 260. Other water droplets 244may pass through insulation 220 and drip from ceiling 232 ontopassengers. This is undesirable for the passengers and causesdiscomfort. The size of space 250 has been substantially exaggerated inFIG. 2 in order to highlight the path through which droplets 244 areintended to travel.

FIG. 3 is a diagram illustrating a section of frame 300 of fuselage 130of aircraft 100 in an exemplary embodiment. FIG. 3 is a view shown byview arrows 3 in FIG. 1. In FIG. 3, various structural components (310,320, 330, 210) are illustrated without insulation for clarity. Frame 300includes stringers 320 and frame elements 310. Stringers 320 connectframe elements 310 (e.g., ribs of the aircraft) together. Windows (e.g.,window 330) penetrate through skin 210.

FIG. 4 is a diagram illustrating section 300 of fuselage 130 withinsulation in an exemplary embodiment. FIG. 4 also utilizes the viewshown by view arrows 3 in FIG. 1. In FIG. 4, the various structuralcomponents (310, 320, 330, 210) depicted in FIG. 3 are now insulated. Asshown in FIG. 4, each frame element 310 is covered by an insulatingliner 312. Furthermore, bays 360 formed between frame elements 310 arefilled with insulating bay blankets 362. Bay blankets 362 are waterproof(e.g., impermeable to water, such that water cannot cross directlythrough the material of bay blankets 362 from either the cabin 230 ofaircraft 100 to skin 210, or from skin 210 of aircraft 100 to cabin230). Bay blankets 362 are also thermally insulating. This ensures thatpassengers within aircraft 100 do not experience substantial temperaturedrops when aircraft 100 travels at cruising altitude. This also ensuresthat liquid water does not permeate through bay blankets 362 whenflowing along an outboard portion of (e.g., the backside/outside of) bayblankets 362.

FIG. 5 is a diagram illustrating a portion of a bay 360 situated at thetop of aircraft 100, as shown in reference number 5 of FIG. 4. Accordingto FIG. 5, bay blanket 500 and bay blanket 550 partially overlap/shingleover each other to form a drainage channel 590 for liquid water to flowdown. Bay blankets 500 and 550 are each made of an insulating andwaterproof material 506. Furthermore, portion 530 of bay blanket 500overlaps portion 580 of bay blanket 550 such that lower portion 530 ofbay blanket 500 is “shingled” over (i.e., outboard with respect to)upper portion 580 of bay blanket 550. In this manner, bay blankets 500and 550 are “shingled” to ensure that water does not leak when drainingfrom one bay blanket to the next.

FIG. 5 further illustrates that bay blankets 500 and 550 are affixed tostringer 320 via fixation elements 502 and 552. Bay blanket 500 isdirectly attached to stringer 320 via fixation element 502. In contrast,bay blanket 550 is attached to stringer 320 indirectly via fixationelement 552. Fixation elements 502 and 552 may comprise any suitablefasteners and/or adhesives, although it may be desirable for fixationelements 550 and 552 to provide for waterproof methods of attachmentthat do not result in leaks/punctures at a bay blanket (e.g., 500, 550).Fixation elements described herein may comprise mated combinations ofhook-and-loop fabric tape, waterproof tape such as BMSS-157 Type 1 Class3 Grade E Form 1 tape, snaps, other adhesive tapes, screws and/or nails,studs, rivets, etc.

FIG. 6 illustrates a bay blanket 500 in a resting configuration in anexemplary embodiment. An outboard surface 508 of bay blanket 500 isshown in detail. Fixation elements 502 are located along the center line504 of bay blanket 500 at outboard surface 508. Furthermore, as shown inFIG. 6, bay blanket 500 includes a leftward lip 610 and a rightward lip610, both of which are waterproof and extend along a length (L) ofblanket 500. Each lip 610 includes multiple strips 613 that extend fromlips 610 towards insulation 506. Each strip 613 comprises a fixationelement 612 capable of attaching bay blanket 500 to one or morestringers 320, a tensile portion 614 configured to resist tension fromthe weight of bay blanket 500, and a fixation element 616 that isattached to insulation 506.

FIG. 7 illustrates bay blanket 500 hanging from fixation elements (612,502) in an installed configuration in an exemplary embodiment. Thisfigure illustrates the role of strips 613 in preserving the shape oflips 610. As shown in FIG. 7, when bay blanket 500 is hung by its ownweight from fixation elements 612 and 502, it partially deforms,resulting in dual troughs/gutters 630 through which water 640 may drain.Strips 613 are drawn taught by the weight of hanging insulation 506.This ensures that lips 610 are properly oriented to deflect any waterthat would otherwise leak off of the side of bay blanket 500.

FIG. 8 illustrates a cut-through front view of an installed bay blanketin an exemplary embodiment. In this embodiment each bay blanket is hungbetween intervening frame elements 310 which are attached to aircraftskin 210. In FIG. 8, gutters 630 are illustrated as bay blanket 500hangs by its own weight from fixation elements 502 and 612. Lips 610each include an overhang 611, which is more clearly visible in thisview. Overhang 611 prevents water from spilling over lips 610 andleaking out of the sides of bay blanket 500.

FIG. 9 is a cut-through diagram illustrating unfolded lips of bayblanket in 500, while FIG. 10 is a cut-through diagram illustratingunfolded lips of bay blanket 500. FIG. 9 shows that when bay blanket 500is first fabricated, fixation elements 616 of strips 613 have not yetbeen affixed to insulation 506. The fixation elements 616 are thenaffixed as shown in FIG. 10. This ensures that lips 610 will not “flop”into an open configuration or otherwise lose their utility while intransit. Strips 613 also ensure that installation of blanket 500 is aneasier process, because lips 610 will not lose their shape duringinstallation or otherwise require micromanagement by a technician.

FIGS. 9-10 also illustrate channeling elements 910. Channeling elements910 provide structural support while also allowing water to flow throughthem. For example, channeling elements 910 may comprise loop fabric tapeattached to lips 610. Such a fabric may resist some amount ofcompression while also defining numerous small, semi-random channels(e.g., porous openings exhibited by porous materials). These channelsallow liquid water 912 to travel through channeling element 910.Channeling element 910 also ensures that if an overhang 611 sags, bows,or dips into contact with insulation 506, water will travel throughchanneling element 910 and rebound off of lip 610 underneath overhang611 instead of damming at lip 610 and then flowing over lip 610. Thisprocess of water 912 flowing through channeling element 910 andrebounding off 914 of lip 610 is illustrated on the right side of FIG.10.

FIGS. 11-13 illustrate a lower portion 530 of a bay blanket 500 in anexemplary embodiment. In this embodiment lower portion 530 is dividedinto regions 1110, 1120, and 1130, which overlap corresponding portionsof another bay blanket (as shown in FIG. 5). Lower region 610 includescorners 1112, which are folded back onto bay blanket 500 towards acenter of bay blanket 500 and affixed to bay blanket 500 by fixationelements 1114. Fixation elements 114 may comprise a waterproof tape suchas BMSS-157 Type 1 Class 3 Grade E Form 1 tape. Affixing and configuringtabs in this manner ensures that water flowing proximate to lips 610 ischanneled towards the center of bay blanket 500 before it passes to anext bay blanket 500. This reduces the chances of leaks in overlappingregions of bay blankets where bay blankets are shingled over withrespect to each other.

FIG. 14 is a block diagram of a bay blanket 1400 in an exemplaryembodiment. In FIG. 14, bay blanket 1400 includes insulation 1406, towhich fixation element 1404 and lips 1410 are attached. Lips 1410include overhangs 1411. Attached to overhangs 1411 are strips 1413,which include fixation elements 1412 for attaching the strip (and bayblanket 1400) to a stringer 1420. Strips 1413 also include tensileportions 1414, and fixation elements 1416 which affix strips 1413 toinsulation 1406. When insulation 1406 hangs from strips 1413 andfixation elements 1404 and 1412, it depresses to form gutters 1430,which channel incoming water through them. While bay blanket 1400 is inoperation, water drains within gutters 1430, deflecting off of lips 1410without spilling off of the side of bay blanket 1400.

Further details of the operations of bay blankets discussed herein willbe discussed with regard to method 1500 of FIG. 15. FIG. 15 is aflowchart illustrating a method for installing a bay blanket in anexemplary embodiment. The steps of method 1500 are described withreference to bay blanket 1400 of FIG. 14, but those skilled in the artwill appreciate that method 1500 may be performed in other environmentswith bay blankets implementing similar innovations. The steps of theflowcharts described herein are not all inclusive and may include othersteps not shown. The steps described herein may also be performed in analternative order.

According to FIG. 15, a bay blanket 1400 is selected for installation(step 1502). Lips 1410 from bay blanket 1400 are identified, and areoriented towards an outboard portion of aircraft 100 (e.g., towards skin210) (step 1504). Bay blanket 1400 is also affixed to the frame ofaircraft 100 via fixation elements (e.g., 612, 502), enabling bayblanket 1400 to hang from the frame of aircraft 100 and form a gutterfor draining water. The method may further comprise folding corners ofbay blanket 1400 towards a center of an outboard portion of the bayblanket, and affixing the corners to the insulation 1406 of bay blanket1400.

In a further embodiment, the method may further comprise repeating theabove steps, once per bay blanket, while overlapping the ends of the bayblankets to form a shingled pattern. That is, blankets that arevertically higher are installed so that their lower portions extend overupper portions of blankets that are vertically lower. The lower portionsare further outboard than the upper portions.

FIG. 16 is a flowchart illustrating a method 1600 for draining water viaa bay blanket 500 in an exemplary embodiment. Method 1600 includesreceiving water along an outboard surface of a bay blanket 500comprising insulation 506 (step 1602). Method 1600 further includesdeflecting water traveling laterally across the bay blanket back towardsa center of the bay blanket by use of waterproof lips 610 that protrudefrom the insulation 506 in an outboard direction towards a frame of theaircraft 100. The waterproof lips 610 are integrated into the insulation506 at left and right sides of the insulation 506 (step 1604).Furthermore, method 1600 includes draining the water along the outboardsurface of the bay blanket 500 downward towards a drain of the aircraft(step 1606). In a further embodiment, step 1606 may include draining thewater across shingled bay blankets such that the water traverses from anupper bay blanket to a lower bay blanket that is shingled under theupper bay blanket. This technique of draining may further includeredirecting draining water from corners of a bay blanket towards thecenter of the bay blanket (e.g., as shown via the structure of FIGS.11-13).

Referring more particularly to the drawings, embodiments of thedisclosure may be described in the context of an aircraft manufacturingand service method 1700 as shown in FIG. 17 and an aircraft 1702 asshown in FIG. 18. During pre-production, exemplary method 1700 mayinclude specification and design 1704 of the aircraft 1702 and materialprocurement 1706. During production, component and subassemblymanufacturing 1708 and system integration 1710 of the aircraft 1702takes place. Thereafter, the aircraft 1702 may go through certificationand delivery 1712 in order to be placed in service 1714. While inservice by a customer, the aircraft 1702 is scheduled for routinemaintenance and service 1716 (which may also include modification,reconfiguration, refurbishment, and so on).

In various embodiments, the improved techniques and components describedherein may be utilized such that materials for bay blankets are procuredin stage 1706, then utilized in stage 1708 in order to assemble thematerials into a bay blanket in stage 1708. In stage 1710, the assembledbay blanket may be attached to a frame of an aircraft, and in stage 1714the bay blanket within the aircraft enhances drainage within an interior1722 while the aircraft is operating. In stage 1716, the bay blanket maybe replaced or repaired by technicians for the aircraft.

Each of the processes of method 1700 may be performed or carried out bya system integrator, a third party, and/or an operator (e.g., acustomer). For the purposes of this description, a system integrator mayinclude without limitation any number of aircraft manufacturers andmajor-system subcontractors; a third party may include withoutlimitation any number of vendors, subcontractors, and suppliers; and anoperator may be an airline, leasing company, military entity, serviceorganization, and so on.

As shown in FIG. 17, the aircraft 1702 produced by exemplary method 1700may include an airframe 1718 with a plurality of systems 1720 and aninterior 1722. Examples of high-level systems 1720 include one or moreof a propulsion system 124, an electrical system 1726, a hydraulicsystem 1726, and an environmental system 1730. Any number of othersystems may be included. Although an aerospace example is shown, theprinciples of the invention may be applied to other industries, such asthe automotive industry.

Apparatus and methods embodied herein may be employed during any one ormore of the stages of the production and service method 1700. Forexample, components or subassemblies corresponding to production stage1708 may be fabricated or manufactured in a manner similar to componentsor subassemblies produced while the aircraft 1702 is in service. Also,one or more apparatus embodiments, method embodiments, or a combinationthereof may be utilized during the production stages 1708 and 1710, forexample, by substantially expediting assembly of or reducing the cost ofan aircraft 1702. Similarly, one or more of apparatus embodiments,method embodiments, or a combination thereof may be utilized while theaircraft 1702 is in service, for example and without limitation, tomaintenance and service 1716.

Although specific embodiments are described herein, the scope of thedisclosure is not limited to those specific embodiments. The scope ofthe disclosure is defined by the following claims and any equivalentsthereof.

1. An apparatus comprising: a frame of an aircraft; and a bay blanketcomprising: insulation; a first waterproof lip that protrudes from theinsulation in an outboard direction towards the frame and extends alonga length of a leftward side of the bay blanket; and a second waterprooflip that protrudes from the insulation in the outboard direction towardsthe frame and extends along a length of a leftward side of the bayblanket; fixation elements that affix each waterproof lip of the bayblanket to the frame of the aircraft; and fixation elements that affix acenter of the bay blanket to the frame; the bay blanket hangs from thefixation elements to form a dual-gutter pathway for channeling water inthe aircraft.
 2. The apparatus of claim 1 wherein: the bay blanket isconfigured to hang from the fixation elements forming a leftward gutterthat channels water in the aircraft proximate to the first waterprooflip, and a rightward gutter that channels liquid water in the aircraftproximate to the second waterproof lip.
 3. The apparatus of claim 1wherein: the fixation elements comprise hook-and-loop fastener material.4. The apparatus of claim 1 wherein: the bay blanket further comprisesstrips that are each attached between one of the waterproof lips and theinsulation.
 5. The apparatus of claim 4 wherein: the fixation elementsthat affix the waterproof lips to the frame are directly attached to thestrips.
 6. The apparatus of claim 1 wherein: each waterproof lip furthercomprises an overhang that extends in a direction parallel to anoutboard surface of the insulation.
 7. The apparatus of claim 6 furthercomprising: a channeling element that continues along a length of theoverhang beneath the overhang, the channeling element comprises a porousmaterial that channels water underneath the overhang when the overhangsags downward towards the insulation.
 8. The apparatus of claim 1wherein: corners at an end of the length of the bay blanket are foldedtowards a center of the bay blanket and affixed to the insulation. 9.The apparatus of claim 1 wherein: the apparatus further comprisesmultiple bay blankets that partially overlap each other in a shingledconfiguration.
 10. A method of draining water for an aircraft, themethod comprising: receiving water along an outboard surface of a bayblanket comprising insulation; deflecting water traveling laterallyacross the bay blanket back towards a center of the bay blanket; anddraining the water along the outboard surface of the bay blanketdownward towards a drain of the aircraft.
 11. The method of claim 10wherein: deflecting the water is performed by use of waterproof lips.12. The method of claim 11, wherein the waterproof lips protrude fromthe insulation in an outboard direction towards a frame of the aircraftand extend along left and right sides of the insulation.
 13. The methodof claim 10, further comprising: hanging the bay blanket from fixationelements attached to the aircraft.
 14. The method of claim 13 furthercomprising: forming a gutter in the bay blanket by causing the bayblanket to droop under its own weight while hanging from the fixationelements.
 15. The method of claim 14 further comprising: draining thewater along the gutter.
 16. A method comprising: selecting a bayblanket; orienting waterproof lips of the bay blanket towards anoutboard portion of an aircraft; and affixing the bay blanket to a frameof the aircraft, thereby enabling the bay blanket to hang from the frameand form a gutter for draining water.
 17. The method of claim 16,further comprising: affixing another bay blanket that partially overlapsthe bay blanket in a shingled configuration.
 18. The method of claim 16,wherein: affixing the bay blanket comprises affixing waterproof lips ofthe bay blanket to the frame of the aircraft.
 19. The method of claim16, further comprising: affixing the bay blanket comprises affixing acenter of the bay blanket to the frame.
 20. The method of claim 16,further comprising: draining water via the bay blanket.